Divisible molded article



, Aug. 25, 1964 R. F. REIFERS ETAL 3,145,896

DIVISIBLE MOLDED ARTICLE Filed Sept. 19, 1962 s Sheets-Sheet 1 3a 50 as 54 70 5444 3a 50 42 3a 3a INVENTORS R/t/mrd E Re/fers Henry A. Lord g- 1964 R. F. REIFERS ETAL 3,145,896

DIVISIBLE MOLDED ARTICLE Filed Sept. 19, 1962 3 Sheets-Sheet 2 INVENTORJ Ric/2am E Rw'fers Henry A. Lord KQRL. (iii Locus K ATTORNEY g- 1964 R. F. REIFERS ETAL 3,145,896

DIVISIBLE MOLDED ARTICLE 5 Sheets-Sheet 3 Filed Sept. 19, 1962 liounyiu/ I INVENTORS c/Iara f. Re/fers Henry A. L 0rd KeRL LL).EFLOCCS' ATTORNEY United States Patent 3,145,896 DIVESIBLE MOLDED ARTICLE Richard F. Reifers, New Canaan, Conn, and Henry A.

Lord, Palmer, Mass, assignors to Diamond National Corporation, New York, N.Y., a corporation of Delaware Filed Sept. 19, 1962, Ser. No. 224,714 3 Claims. (Cl. 2292.5)

This invention relates generally to molded articles and more particularly to an improved molded pulp egg carton which is divisible or separable to form two individual and structurally functional carton segments.

Divisible or separable molded cartons heretofore proposed generally served only the expressed purpose of dividing or segregating a quantity of eggs contained of an original carton, and the separated carton segments generally have not afforded the necessary protection of the eggs when transported from the retail establishments, and additionally the carton segments do not lend themselves to adequate display or include ventilation and egg-observing aperture means, or include a separable portion which is inherently strong after separation unless it is of such a construction wherein initial dividing was relatively difficult.

Primary objects of the present invention are to provide a novel divisible or separable molded pulp egg carton and carton segments overcoming the shortcomings of the prior art, and which in the original and unseparated cartons afford ventilation and egg viewing means; the original carton including a reinforcing structure maintaining the original carton as a single unit and lending itself to a natural division into separated carton segments; the individual or separated carton segments having an individual structural strength readily protecting the eggs at both ends and having a substantially symmetrical and pleasing appearance lending themselves to display; the separated carton segments further including individual lock flap means; and the originally produced carton lending itself to ready and economical production as well as aifording ready denesting on automatic equipment during the packing of eggs in the undivided cartons.

Other objects in the nature and advantages of the present invention will become apparent from the following description taken in conjunction with the accompanying drawings, wherein:

FIG. 1 is a front elevation of a molded pulp egg carton incorporating the invention;

FIG. 2 is a top plan View of FIG. 1;

FIG. 3 is an enlarged end elevation looking, from left to right at FIG. 1;

FIG. 4 is an enlarged vertical section taken on the plane of line 44 of FIG. 2 on the central transverse axis of the carton; showing the end elevation appearance of one of the carton segments after the carton has been divided;

FIG. 5 is an enlarged, fragmentary, plan view looking into an open carton and showing the areas of separation of the lid and bottom section of the carton;

FIG. 6 is an enlarged, fragmentary, vertical section taken on the plane of line 6-6 of FIG. 4 on the longitudinal axis of the carton, and showing the separable reinforcing structure between the unseparated carton segments; and

FIG. 7 is an enlarged fragmentary vertical section taken on the plane of line 77 of FIG. 4, with a portion of one of the lock flaps broken away for purposes of clarity.

Before describing the features and details of the novel carton, it will be understood by those skilled in the art that the carton is produced on suitable molds from the slurry of pulp material to provide a pulp preform which is subsequently subjected to drying, pressing, re-working, etc.

Considering FIGS. 1-3, the novel egg carton is indicated generally at 10 and comprises a cellular bottom section 12, and a lid section 14. The bottom section of the originally produced carton will hold one dozen eggs and is conventionally described as a 2 x 6. As clearly seen in FIGS. 1 and 2, the bottom and lid sections 12 and 14 are secured on the central transverse axis upon which line 4-4 of FIG. 2 falls, by a separable reinforcing structure indicated generally at 16. The separable structure 16 when divided will provide individual and structurally stable carton segments 18 and 20.

The bottom section 12 of the carton comprises a plurality of depending cells 22, each cell including; see FIG. 5, a bottom wall 24 integral with vertically extending side walls and right angularly disposed transverse and longitudinal saddle portions 26 and 28, respectively. The saddles 26 and 28 merge into vertically extending steeply inclined or tapered posts, each carton segment 18 and 20 incorporating two of such posts indicated at 30 and 30', respectively as shown by dotted lines in FIG. 1. The vertical posts of the present embodiment are shown as extending above the peripheral margins 32 and 32 of the bottom section 12, however, the novel features of the invention could readily be incorporated in a carton which includes posts which terminate substantially in the plane of a peripheral margin of the bottom section 12.

Bottom section 12 has hingedly connected at 34, 34, see FIGS. 1 and 5, longitudinally spaced lock flaps 36, 36, respectively, which have, forwardly-projecting abutment or lock buttons 38 and 38.

The lid section 14 is hingedly connected at 40 and 40' to the bottom section 12 and each of the carton segments 18 and 20 respectively include a substantially planar top 42 and 42' integral with depending front and rear side Walls 44, 46 and 44', 46', respectively, terminating in peripheral margin portions 48 and 48'. The side walls 44 and 44' respectively include transverse apertures 50 and 50', respectively, removably receiving lock buttons 38 and 38, respectively.

The carton segments 18 and 20 include, integral with the top and side walls thereof, depending end walls 52 and 54 and 52' and 54', respectively, the end walls 54, 54 being inner converging end walls of the lid sections of the respective carton segments. The end walls 52 and 52' each include therein, as most clearly seen in FIG. 3, a downwardly opening U-shaped notch portion 58 and 58 which provides a ventilation and egg-observation aperture in the carton. The notched portions 58 and 58 are bordered by transverse reinforcing flange portions 60 and 60', respectively, which terminate at the peripheral margins 48 and 48' to reinforce the carton segment lid sections and essentially provide handles by which the carton may be readily lifted. The bordering ends 59 and 61 of the notches 58, 58'; see FIG. 3, are disposed at substantially the same angle as that of the front and rear side walls 44, 46 and 44', 46' ie, parallel to walls 44, 46 and 44', 46'. When the carton is intact or separated, vertical loading will be transmitted directly to the bottom section without causing rupture of the cover at the notches 58, 58.

The inner ends of the depending side walls 44, 46 and 44', 46' of the carton segments merge into the inner end walls 54 and 54, respectively, the respective peripheral flanges 32, 32' and 48, 48' being notched out at 62 and 64 and converging at the central transverse plane of the carton on a transverse line of separation 66 and 68 formed by suitable perforations. Although the lines of separation 66 and 68 extend transversely through the divisible or separable reinforcing structure 16, this structure is inherently strong enough prior to manual separation to prevent the carton segments 18 and 20 from breaking apart when only one segment is being held in an individuals hand. V I

Formed integrally with the inner end walls 54 and 54' of the respective carton segments is a longitudinally extending upper, tunnel-like element 70 which when separated at the line of separation 66 provides reinforcing flange segments 80, 80 overlying a downwardly opening notch portion 82 and 82 in the respective carton seg ments. The downwardly opening notch portion 82, 82 of the respective carton segments is slightly higher than the downwardly opening notches 58 and 58' and provides in the undivided carton a through opening between the respective carton segments to provide good ventilation for the eggs contained and stored therein. When the carton segments are separated at the line 66 and 68, the notched in portions 62 and 64 providing a natural point at which the segments may be twisted and separated. The downwardly opening notched portions 82 and 82 will permit the individual carton segments to have good ventilation as well as to permit the eggs of the end cells to be readily examined by purchasers.

The bordering ends 83 and 85 of the notch portions 82, 82; see FIG. 4, are substantially parallel to the carton side walls 44, 46 and 44', 46', respectively, to afford the proper vertical load transmittal.

The lower altitude at the notches 58, 58' affords necessary structural strength and prevents cover rupture at the notches during vertical loading.

It will be readily apparent that the independent carton segments 18 and 20 when separated from each other will have substantially identical end views, i.e. the carton will have an essentially symmetrical appearance; this being apparent when comparing FIGS. 3 and 4.

The bottom section 12 includes a polygonal central panel 84 divided by the line of separation 68; see FIG. 5, into substantially triangular segments 86 and 86. The panel 84 is disposed substantially in the plane of the peripheral margins 32 and 32' of the respective bottom sections of the separated carton segments. Depending from opposite sides 88 and 90 of the panel 84 are low V- shaped reinforcing beams 92 and 94 which are divided by the line of separation 68. These beam-like elements 92 and 94 extend longitudinally beneath the tunnel element 70 and reinforce the unseparated carton against bending moments about the lines of separation 66 and 68. The V-shaped beam-like elements have sides 92 and 94 which are generally in angular alignment with the respective outer and inner surfaces of the vertically extending posts 30 and front and rear walls of the cells in the bottom section and thus they are disposed in what might be described as a non-load area to accordingly eliminate or avoid structural faults in the carton or carton segments when they are subject to vertical loading when they are stacked and loaded one upon the other.

Considering FIG. 1, it will be immediately observed that the tunnel-like elements 70 and the beam-like elements 92 and 94 substantially reinforce the carton when it is undivided. Each of the elements resists separation of the other during upward or downward bending moments between the respective adjacent and undivided carton segments. Additionally, the notched in portions 62 and 64 provide a normal and natural breaking line extending into the perforations at lines of separation 66 and 68. This facilitates the ready separation of the two carton segments, and when this is accomplished the carton segments will have structurally stable end walls, substantially identical and yet affording visual access to the eggs within the carton, and good ventilation thereof. Additionally, each of the separated segments have hand grip portions at the opposite ends as does the unseparated carton. Still further, each of the separated segments incorporate individual lock flap means therein so that the carton segments 18 and 20 function as independent units.

The cover section, it will be observed, includes therein notched portions approximately one-half the altitude of the cover. The tunnel merges into inclined walls 54, 54' and the front and side walls 44, 46 and 44', 46. This wall inclination not only provides a visually pleasing appearance in the carton and separated carton segments, but maintains center flexing to a minimum.

Further, the V-notches as seen in FIG. 4, are approximately equal to the depth of the notches or connecting bridges between adjacent cells. The V-notches are connected by flanges substantially in the same plane or altitude as the bordering flanges of the bottom or cell section. This construction lends itself to good internal structural geometry and carton stability as well as providing carton separation and a stable geometry for the separate carton separation and a stable geometry for the separate carton segments.

It will be obvious to those skilled in the art that various changes may be made without departing from the scope of the invention and therefore the invention is not limited to what is shown in the drawings and described in the specification but only as indicated in the appended claims.

What is claimed is:

1. An egg carton segment comprising a lid and cellular bottom section, said bottom section including steeply inclined side and end Walls terminating in peripheral margin portions, a plurality of normally disposed saddle portions extending inwardly from said side and end walls and merging into a pair of steeply tapered posts extending above the peripheral margin of said bottom section and spaced inwardly from said side and end walls and forming two parallel rows of egg cells with three cells to a row, said lid section including a substantially planar top integral with depending side and end walls, one of said end section side walls being hingedly connected to the peripheral margin of one of said bottom section side walls and the other lid section side wall including longitudinally spaced, lock-flap engaging means, said other bottom section side wall including a pair of longitudinally spaced lock flaps hingedly connected to the peripheral margin thereof and respectively detachably engageable with said longitudinally spaced lock-flap engaging means, said lid section end walls including downwardly opening notches forming ventilation and egg observation apertures in the ends thereof, one end wall of said bottom section including a pair of spaced V-shaped notched portions when viewed in elevation and having reinforcing flanges terminating at the peripheral margin of said bottom section.

2. A separable one-piece molded pulp egg carton comprising a lid and cellar bottom section, said lid section being hingedly connected to said bottom section along one side edge thereof, said bottom section including lock flap means hingedly connected along the side edge opposite that to which the lid section is hingedly connected, said lock flap means including means detachably engageable with said lid section, the improvement comprising separable, intermediate carton-reinforcing structure forming similar end structure on a pair of separate carton segments formed from said separable egg carton, said lid section comprising depending end and side walls integral with a substantially planar top panel, said end walls including downwardly opening notch portions forming ventilation and observation apertures at opposite ends of said carton, said separable, intermediate carton-reinforcing structure including a pair of converging, intermediate transverse walls terminating in a separable, downwardlyopening tunnel portion forming a through opening in said one-piece carton and providing ventilation and observation apertures in said carton from end-to-end, said lid section including longitudinally projecting reinforcing flanges bordering each of said notch portions and said tunnel and extending laterally from said notch portions for engagement on the upper peripheral edge of said bottom section, said tunnel portion forming reinforcing flanges at the ventilation and observation apertures of said carton segments, said cellular bottom section including steeply tapered post portions having cells formed thereabout and including a terminal end portion projecting vertically above the peripheral edge of said bottom section and normally engageable with the inner surface of said planar top of said lid section for reinforcing said carton and the carton segments formed therefrom against vertical loading of the egg carton, said separable, intermediate carton-reinforcing structure including an intermediate, separable polygonal panel in said bottom section and substantially coplanar with the outer marginal edge of said bottom section.

3. The structure as claimed in claim 2, in which the cellular bottom section comprises longitudinally disposed, separable, intermediate reinforcing structure including V- shaped, longitudinally disposed, beam-like ribs disposed 6 transversely of and at opposite sides of said polygonal panel in said bottom section, said V-shaped, beam-like ribs including converging sides substantially coplanar With respective outer side walls of said bottom section and opposed surfaces of opposite sides of said tapered post portions.

References Cited in the file of this patent UNITED STATES PATENTS 2,078,488 Farnham Apr. 27, 1937 2,093,280 Koppelman Sept. 14, 1937 2,455,295 Cox Nov. 30, 1948 2,655,303 Cox Oct. 13, 1953 2,974,847 Hurn Mar. 14, 1961 FOREIGN PATENTS 30,640 Finland Mar. 31, 1960 800,949 Great Britain Sept. 3, 1958 

1. AN EGG CARTON SEGMENT COMPRISING A LID AND CELLULAR BOTTOM SECTION, SAID BOTTOM SECTION INCLUDING STEEPLY INCLINED SIDE AND END WALLS TERMINATING IN PERIPHERAL MARGIN PORTIONS, A PLURALITY OF NORMALLY DISPOSED SADDLE PORTIONS EXTENDING INWARDLY FROM SAID SIDE AND END WALLS AND MERGING INTO A PAIR OF STEEPLY TAPERED POSTS EXTENDING ABOVE THE PERIPHERAL MARGIN OF SAID BOTTOM SECTION AND SPACED INWARDLY FROM SAID SIDE AND END WALLS AND FORMING TWO PARALLEL ROWS OF EGG CELLS WITH THREE CELLS TO A ROW, SAID LID SECTION INCLUDING A SUBSTANTIALLY PLANAR TOP INTEGRAL WITH DEPENDING SIDE AND END WALLS, ONE OF SAID END SECTION SIDE WALLS BEING HINGEDLY CONNECTED TO THE PERIPHERAL MARGIN OF ONE OF SAID BOTTOM SECTION SIDE WALLS AND THE OTHER LID SECTION SIDE WALL INCLUDING LONGITUDINALLY SPACED, LOCK-FLAP ENGAGING MEANS, SAID OTHER BOTTOM SECTION SIDE WALL INCLUDING A PAIR OF LONGITUDINALLY SPACED LOCK FLAPS HINGEDLY CONNECTED TO THE PERIPHERAL MARGIN THEREOF AND RESPECTIVELY DETACHABLY ENGAGEABLE WITH SAID LONGITUDINALLY SPACED LOCK-FLAP ENGAGING MEANS, SAID LID SECTION END WALLS INCLUDING DOWNWARDLY OPENING NOTCHES FORMING VENTILATION AND EGG OBSERVATION APERTURES IN THE ENDS THEREOF, ONE END WALL OF SAID BOTTOM SECTION INCLUDING A PAIR OF SPACED V-SHAPED NOTCHED PORTIONS WHEN VIEWED IN ELEVATION AND HAVING REINFORCING FLANGES TERMINATING AT THE PERIPHERAL MARGIN OF SAID BOTTOM SECTION. 